US6957030B2ExpiredUtilityPatentIndex 88

Method and apparatus for making signs

Assignee: GERBER SCIENTIFIC INT INCPriority: Feb 8, 2002Filed: Feb 7, 2003Granted: Oct 18, 2005

Est. expiryFeb 8, 2022(expired)· nominal 20-yr term from priority

Inventors:BAKER JR PETER R GUCKIN MARK E LOGAN DAVID J CROFT RUSSELL F

B44C 1/1733G03G 13/16G03G 8/00G03G 15/6585B41M 5/00B44C 1/105G03G 7/0006B44C 1/17B41M 5/0256G03G 7/00G03G 2215/00801

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Claims

Abstract

An apparatus for digitally generating an image comprises a photoconductor assembly, a corona assembly, and a light source assembly to generate a latent image on the photoconductor. The apparatus also includes a developer assembly that includes a developer, such as powder paint, to generate an image. The apparatus may include a fuser for generating a film image. The apparatus of the present invention may include a cartridge for storing and digitally applying adhesive to the image. Furthermore, the apparatus of the present invention includes a controller for selectively controlling voltages to control thickness of the image. Additionally, apparatus may include a consumable sheet to remove excess adhesive from the substrate.

Claims

exact text as granted — not AI-modified

1. A method for generating an image product comprising the steps of:
generating an image on a carrier sheet surface, said image having sufficient retention property to releasably remain on said carrier sheet surface;
applying a pressure sensitive adhesive over said carrier sheet surface with said image;
joining said carrier sheet surface with said image and with said pressure sensitive adhesive with a substrate; and
removing from said substrate said carrier sheet with excess pressure sensitive adhesive adhered to said surface, leaving said substrate with said image adhered thereto, thereby generating an image product.

2. The method according to claim 1 further comprising an intermediate step of:
applying pressure to ensure attachment of said image with said adhesive onto said substrate prior to removing said carrier sheet with excess adhesive from said substrate and said image.

3. The method according to claim 2 wherein said adhesive has preference for said carrier sheet surface rather than said substrate.

4. The method according to claim 1 wherein said image is reverse printed onto said carrier sheet surface.

5. The method according to claim 1 wherein said adhesive, said carrier sheet surface and said substrate are selected such that said adhesive has preference for said carrier sheet surface rather than said substrate.

6. The method according to claim 1 wherein a bond between said image and said adhesive is stronger than a bond between said image and said carrier sheet surface.

7. The method according to claim 1 wherein a bond between said adhesive and said substrate is stronger than a bond between said image and said carrier sheet surface.

8. The method according to claim 1 wherein a bond between said carrier sheet surface and said adhesive is stronger than a bond between said adhesive and said substrate.

9. The method according to claim 1 wherein said adhesive, said carrier sheet surface and substrate are selected such that a bond between said image and said adhesive is stronger than a bond between said image and said carrier sheet surface, a bond between said adhesive and said substrate is stronger than a bond between said image and said carrier sheet surface, and a bond between said carrier sheet surface and said adhesive is stronger than a bond between said adhesive and said substrate.

10. The method according to claim 1 wherein said film image is printed onto said carrier sheet surface using a laser printer.

11. The method according to claim 1 wherein said film image is printed onto said carrier sheet surface using a thermal printer.

12. The method according to claim 1 wherein said film image is printed onto said carrier sheet surface using an ink jet printer.

13. The method according to claim 1 wherein said film image is printed onto said carrier sheet surface using a silk screening process.

14. The method according to claim 1 wherein said image is a film image.

15. The method according to claim 14 wherein said film image is a durable film.

16. The method according to claim 15 wherein said durable film comprises powder paint.

17. The method according to claim 15 wherein said durable film comprises pigmented resin.

18. The method according to claim 15 wherein said durable film comprises UV curable ink.

19. The method according to claim 1 further comprising a subsequent step of:
curing said substrate with said image to ensure attachment of said image with said adhesive to said substrate.

20. The method according to claim 1 further comprising a step of:
fusing said image onto said substrate.

21. The method according to claim 20 wherein said step of fusing is performed by UV fusing.

22. The method according to claim 20 wherein said step of fusing is performed by heat fusing.

23. The method according to claim 20 wherein said step of fusing is performed by combination of UV and heat fusing.

24. The method according to claim 20 wherein said step of fusing is performed by infrared fusing.

25. The method according to claim 1 wherein said adhesive is applied digitally over said image.

26. The method according to claim 1 wherein said adhesive includes a colorant.

27. The method according to claim 1 wherein said image is comprised of powder paint digitally applied on said carrier sheet.

28. The method according to claim 27 wherein said image becomes a film image upon curing.

29. The method according to claim 28 wherein said film image is a durable film image.

30. The method according to claim 27 wherein said powder paint comprises a resin and pigment.

31. The method according to claim 27 wherein said powder paint comprises resin and pigment and is outdoor durable and UV stable.

32. The method according to claim 1 wherein said image is fused on said carrier sheet before removal to said substrate.

33. The method according to claim 1 wherein said adhesive is applied selectively onto said carrier sheet.

34. The method according to claim 33 wherein said adhesive is applied digitally onto said carrier sheet.

35. The method according to claim 1 wherein said adhesive is applied globally onto said carrier sheet.

36. The method according to claim 35 wherein said adhesive includes a colorant.

37. The method according to claim 1 wherein additional layers of adhesive are digitally applied onto said image.

38. Apparatus for generating an image comprising:
means for applying at least one colorant onto a carrier sheet surface coated with a pressure sensitive adhesive layer to generate an image atop of said pressure sensitive adhesive layer; and
means for removing excess pressure sensitive adhesive from said carrier sheet surface to result in said image being disposed atop of said carrier sheet surface with pressure sensitive adhesive being disposed therebetween.

39. The apparatus according to claim 38 further comprising: means for curing said image.

40. The apparatus according to claim 38 further comprising: means for fusing said image.

41. The apparatus according to claim 40 wherein said means for fusing is a non contact fuser.

42. The apparatus according to claim 38 wherein said means for applying at least one colorant is an ink jet system.

43. The apparatus according to claim 38 wherein said means for applying at least one colorant is an electrophotographic system.

44. The apparatus according to claim 38 wherein said means for applying at least one colorant is an electrostatic system.

45. The apparatus according to claim 38 wherein said means for applying at least one colorant is a thermal transfer system.

46. The apparatus according to claim 38 wherein said means for removing said excess adhesive is a system bringing a consumable sheet into contact with said adhesive to remove said excess adhesive leaving said image disposed atop of said carrier sheet with said adhesive layer sandwiched therebetween.

47. The apparatus according to claim 46 wherein said means for removing said excess adhesive comprises:
a supply roll for dispensing said consumable sheet; and
a take up roll for taking up said consumable sheet with said excess adhesive disposed thereon.

48. The apparatus according to claim 47 further comprising:
a pressure roller disposed between said supply roll and said take up roll and substantially adjacent to said consumable sheet to apply pressure thereto to promote bonding between said consumable sheet and said excess adhesive.

49. The apparatus according to claim 46 wherein said consumable sheet is ink foil for a thermal transfer printer.

50. The apparatus according to claim 46 wherein said consumable sheet functions as a protective sheet and is removed from said carrier sheet at a later time.

51. The apparatus according to claim 38 further comprising:
means for printing with predetermined background color over an entire image to remove excess adhesives to define an image background perimeter to allow subsequent printing over some portion of said image background perimeter with at least one color to generate a multi-color image.

52. The apparatus according to claim 51 wherein said predetermined background color is white.

53. The apparatus according to claim 51 wherein said predetermined background color is clear.

54. The apparatus according to claim 38 further comprising:
means for printing with predetermined background color over an entire image to remove excess adhesives to define an image background perimeter to allow subsequent printing over some portion of said image background perimeter with at least one half-tone color to generate a half-tone image.

55. A method for generating a film image comprising the steps of:
providing a carrier sheet having a surface with a pressure sensitive adhesive layer removably attached thereto;
printing an image onto said carrier sheet surface with the adhesive layer such that said image is disposed atop of said pressure sensitive adhesive layer; and
removing from said carrier sheet surface substantially all excess pressure sensitive adhesive such that said image remains on said carrier sheet surface with said pressure sensitive adhesive layer sandwiched therebetween.

56. The method according to claim 55 wherein said image is printed on a laser printer.

57. The method according to claim 55 wherein powder paint is used to print said image.

58. The method according to claim 55 wherein said image is printed on an ink jet printer.

59. The method according to claim 58 wherein UV cure ink is used to print said image.

60. The method according to claim 55 wherein said image is printed on a thermal transfer printer having an ink foil.

61. The method according to claim 60 wherein said excess adhesive is removed with said ink foil.

62. The method according to claim 61 wherein said excess adhesive adheres to said ink foil.

63. The method according to claim 55 wherein said step of printing further comprises the steps of:
printing with predetermined background color over an entire image to remove excess adhesives to define an image background perimeter; and
printing over some portion of said image background perimeter with at least one color to generate a multi-color image.

64. The method according to claim 63 wherein said predetermined background color is white.

65. The method according to claim 55 wherein said step of printing further comprises the steps of:
printing with predetermined background color over an entire image to remove excess adhesives to define an image background perimeter; and
printing over some portion of said image background perimeter with at least one half-tone color to generate a half-tone image.

66. The method according to claim 63 wherein said predetermined background color is clear.

67. The method according to claim 66 wherein said colorant is white.

68. The apparatus according to claim 38 further comprising means to apply said adhesive digitally over said carrier sheet.

69. The apparatus according to claim 68 wherein said means to apply adhesive digitally over said carrier sheet is adapted to apply said adhesive globally.

70. The apparatus according to claim 68 wherein said means to apply adhesive digitally over said carrier sheet is adapted to apply said adhesive selectively so as to at least cover substantially the portion within the boundaries of a predetermined image to be applied.

71. The apparatus according to claim 38 wherein said colorant includes dye.

72. The apparatus according to claim 38 wherein said colorant includes pigment.

73. The method according to claim 55 wherein said adhesive is digitally applied over said carrier sheet.

74. The method according to claim 55 wherein said digital application of said adhesive is global.

75. The method according to claim 55 wherein said digital application of said adhesive is selective so as to at least cover substantially the portion within the boundaries of a predetermined image to be applied.

76. Apparatus for generating an image comprising:
means for applying at least one colorant onto a carrier sheet surface coated with a pressure sensitive adhesive layer to generate an image atop of said adhesive layer, said adhesive layer containing at least one colorant; and
means for removing excess adhesive from said carrier sheet surface to result in said image being disposed atop of said carrier sheet surface with adhesive being disposed therebetween.

77. A method for generating a film image comprising the steps of:
providing a carrier sheet surface with a layer of pressure sensitive adhesive containing at least one colorant;
printing an image onto said carrier sheet surface with said adhesive layer such that said image is disposed atop of said adhesive layer; and
removing from said carrier sheet substantially all excess adhesive such that said image remains on said carrier sheet with said adhesive layer sandwiched therebetween.

78. A method for generating an image product comprising the steps of:
generating an image on a carrier sheet surface, said image having sufficient retention property to releasably remain on said carrier sheet surface;
applying a pressure sensitive adhesive to cover said image with at least one adhesive layer, and areas outside of said image with excess adhesive;
joining said carrier sheet surface with said image and with said adhesive with a substrate; and
removing from said substrate said carrier sheet surface with substantially all of said excess adhesive, leaving said substrate with said image adhered thereto, thereby generating an image product.

79. A method for generating an image product comprising the steps of:
generating an image with a curable medium on a carrier sheet surface;
curing said image;
applying an adhesive to cover said cured image with a pressure sensitive adhesive layer, and areas outside of said image with excess adhesive;
heating a thermoplastic transfer film to a softened or tacky state, said adhesive and said transfer film being selected such that said adhesive has a preference for said carrier sheet surface rather than said transfer film;
joining said carrier sheet surface with said cured image and with said adhesive with said heated transfer film;
permitting said transfer film to cool to a hard, durable state; and
removing said carrier sheet surface with excess adhesive from said transfer film, leaving said transfer film with said image adhered thereto, thereby generating an image product.

80. A method for generating an image product in a printing apparatus comprising the steps of:
generating an image on a carrier sheet surface having a pressure sensitive adhesive layer disposed thereon;
joining said carrier sheet with said image and with said adhesive with a consumable sheet; and
removing said consumable sheet with excess adhesive from said carrier sheet surface, leaving said carrier sheet with said image adhered thereto, thereby generating an image product.

81. Apparatus for generating an image comprising:
means for applying at least one colorant onto a carrier sheet surface digitally coated with a pressure sensitive adhesive layer to generate an image atop of said adhesive layer;
means for joining said carrier sheet with said image and with said adhesive in contact with a consumable sheet; and
means for removing said consumable sheet with excess adhesive from said carrier sheet surface to result in said image being disposed atop of said carrier sheet with said adhesive being disposed therebetween.

82. Image product according to claim 81 wherein said adhesive layer is digitally applied selectively to said substrate.

83. Image product according to claim 82 wherein said adhesive is digitally applied globally onto said substrate.

84. Apparatus for generating an image comprising:
means for digitally applying a layer of pressure sensitive adhesive onto a carrier sheet surface;
means for applying at least one colorant onto said carrier sheet surface coated with said adhesive layer to generate an image atop of said adhesive layer; and
a device for bringing a consumable sheet in face-to-face contact with said carrier sheet, and for removing said consumable sheet therefrom, said consumable sheet and said adhesive being selected such that said adhesive has a preference for said consumable sheet rather than said carrier sheet surface to facilitate removal of excess adhesive from said carrier sheet along with said consumable sheet, to result in said image being disposed atop of said carrier sheet with adhesive being disposed therebetween.

85. The apparatus according to claim 84 wherein said adhesive contains a colorant.

86. The apparatus according to claim 85 wherein said colorant is white.

87. Apparatus for generating an image comprising:
a device for applying a pressure sensitive adhesive layer containing a colorant onto a carrier sheet surface;
means for applying at least one colorant including at least one of a powder paint and powder toner onto said carrier sheet surface coated with said adhesive layer to generate an image atop of said adhesive layer; and
a device for bringing a consumable sheet in contact with said carrier sheet for removing excess adhesive from said carrier sheet surface to result in said image being disposed atop of said carrier sheet with adhesive being disposed therebetween.

88. Image product produced according to a method for generating an image product comprising the steps of:
generating an image on a carrier sheet surface, said image having sufficient retention property to releasably remain on said carrier sheet surface;
applying a pressure sensitive adhesive over said carrier sheet surface with said image;
joining said carrier sheet with said image and with said adhesive with a substrate, said substrate and said adhesive being selected such that said adhesive has a preference for said carrier sheet surface rather than said substrate; and
removing from said substrate said carrier sheet surface with excess adhesive adhered thereto, leaving said substrate with said image adhered thereto.

89. Image product produced according to a method for generating an image product comprising the steps of:
applying at least one colorant onto a carrier sheet surface coated with a pressure sensitive adhesive layer to generate an image atop said adhesive layer; and
removing excess adhesive from said carrier sheet surface to result in said image being disposed atop of said carrier sheet surface with adhesive being disposed therebetween.

90. Image product produced according to a method for generating an image product comprising the steps of:
generating an image on a carrier sheet surface having a pressure sensitive adhesive layer disposed thereon;
joining said carrier sheet with said image and with said adhesive with a consumable sheet; and
removing said consumable sheet with excess adhesive from said carrier sheet surface, leaving said carrier sheet with said image adhered thereto.

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